Continuous pressed laminates

Abstract

A continuous pressed laminate includes a first layer of resin impregnated paper and at least one layer of fiber reinforced veil wherein each layer of the fiber reinforced veil is impregnated with a binder and a filler composition and wherein the layer of fiber reinforced veil following impregnation and prior to pressing has a weight per unit area of between about 50 to about 1250 g/m 2 .

1 . A continuous pressed laminate, comprising: 
 a first layer of resin impregnated paper; and    at least one layer of fiber reinforced veil, each layer of said fiber reinforced veil being impregnated with a binder and a filler composition;    wherein said at least one layer of fiber reinforced veil has a weight per unit area of between about 50 to about 1250 g/m 2  following impregnation and prior to pressing.    
   
   
       2 . The continuous pressed laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil has a weight per unit area of between about 75 to about 750 g/m 2  following impregnation and prior to pressing.  
   
   
       3 . The continuous pressed laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil has a weight per unit area of between about 100 to about 600 g/m 2  following impregnation and prior to pressing.  
   
   
       4 . The continuous pressed laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil has a base weight per unit area of between about 20 to about 200 g/m 2 .  
   
   
       5 . The continuous pressed laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil has a base weight per unit area of between about 30 to about 120 g/m 2 .  
   
   
       6 . The continuous pressed laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil has a base weight per unit area of between about 40 to about 100 g/m 2 .  
   
   
       7 . The continuous pressed laminate of  claim 1 , wherein said impregnated fiber reinforced veil comprises between about 2 and about 50 weight percent reinforcement fibers, between about 10 and about 70 weight percent resin and between about 0 and about 80 weight percent filler.  
   
   
       8 . The continuous pressed laminate of  claim 7 , wherein said resin is selected from a group of resins consisting of phenol formaldehyde, melamine formaldehyde, urea formaldehyde, crosslinkable acrylates, crosslinkable acrylics, self-crosslinkable acrylates, self-crosslinkable acrylics, epychlorohydrin polyamide, epychlorohydrin polyamine, epoxy and mixtures thereof.  
   
   
       9 . The continuous pressed laminate of  claim 8 , wherein said filler is selected from a group of fillers consisting of aluminum trihydrate, calcium carbonate, magnesium hydroxide, metal hydroxides, metal carbonates, titanium oxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, magnesium carbonate, aluminum oxide, iron oxide, ethylenediamine phosphate, guanidine phosphate, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, expandable graphite, glass micro beads and mixtures thereof.  
   
   
       10 . The continuous pressed laminate of  claim 9 , wherein said resin and filler composition includes between about 10 and about 60 weight percent resin and between about 0 and about 85 weight percent filler.  
   
   
       11 . The continuous pressed laminate of  claim 7 , wherein said resin is a phenol formaldehyde/melamine formaldehyde/hardener mixture.  
   
   
       12 . The continuous pressed laminate of  claim 11 , wherein said filler is selected from a group of fillers consisting of aluminum trihydrate, calcium carbonate, magnesium hydroxide and mixtures thereof.  
   
   
       13 . The continuous pressed laminate of  claim 12 , wherein said resin is provided at a ratio of about 25-75% phenol formaldehyde, about 25-75% melamine formaldehyde and about 2-20% hardener.  
   
   
       14 . The continuous pressed laminate of  claim 13 , wherein said resin and filler composition includes between about 10 and about 60 weight percent resin and between about 0 and about 85 weight percent filler.  
   
   
       15 . The continuous pressed laminate of  claim 1 , further including a layer of backing paper wherein said veil is sandwiched between said first layer of resin impregnated paper and said backing paper.  
   
   
       16 . The continuous pressed laminate of  claim 1 , further including a layer of parchment paper wherein said veil is sandwiched between said first layer of resin impregnated paper and said parchment paper.  
   
   
       17 . The continuous pressed laminate of  claim 1 , further including a second layer of resin impregnated paper wherein said veil is sandwiched between said first and second layers of resin impregnated paper.  
   
   
       18 . The continuous pressed laminate of  claim 17 , wherein said first and second layers of resin impregnated paper are melamine impregnated decorative paper.  
   
   
       19 . The continuous pressed laminate of  claim 1 , wherein said fiber reinforced veil is woven.  
   
   
       20 . The continuous pressed laminate of  claim 1 , wherein said fiber reinforced veil is nonwoven.  
   
   
       21 . The continuous pressed laminate of  claim 1 , wherein said fiber reinforced veil is made from at least one layer of woven material and at least one layer of nonwoven material.  
   
   
       22 . The continuous pressed laminate of  claim 1 , wherein said fiber reinforced veil includes reinforcing fibers selected from a group consisting of glass fibers, basalt fibers, silica fibers, inorganic fibers and mixtures thereof.  
   
   
       23 . The continuous pressed laminate of  claim 22 , wherein said glass fibers are chopped.  
   
   
       24 . The continuous pressed laminate of  claim 23 , wherein said chopped glass fibers are selected from a group consisting of chopped strands, chopped rovings, chopped individual glass fibers and mixtures thereof.  
   
   
       25 . A method of making a continuous pressed laminate, comprising: 
 pressing a first layer of resin impregnated paper and at least one layer of fiber reinforced veil together at a pressure of between about 5 kg/cm 2  and about 60 kg/cm 2  while simultaneously heating said layers to a temperature of about 120° C. to about 250° C. to produce a laminate, said at least one layer of fiber reinforced veil having a weight per unit area of between about 50 to about 1250 g/m 2  following impregnation and prior to pressing.